DEPARTMENT OF MECHANICAL ENGINEERING

JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

MODULE 4: Coupling
Design of Rigid and Flexible Couplings
Coupling is a mechanical device that permanently joins two rotating shafts to each
other.

Applications:

i. To join output shaft of an engine to the input shaft of a hydraulic pump to raise water
from well.
ii. To join output shaft of electric motor to the input shaft of a gearbox in machine tools.
iii. To join output shaft of electric motor to the input shaft of a compressor.

Difference between Clutch and Coupling:

Coupling is a permanent connection, while the clutch can connect or disconnect two
shafts at the will of the operator.

Classification of Coupling:

Two types:

1) Rigid Coupling
2) Flexible Coupling

Rigid Couplings:

Rigid Couplings require perfect alignment of the shafts to be joined. Most widely used
rigid couplings are:

i. Sleeve or Box or Muff Coupling

ii. Clamp or Split-muff or Compression Coupling
iii. Flange Coupling

Flexible Couplings:

If the shafts to be joined are laterally misaligned (axes parallel but off-set), or angularly
misaligned (axes may intersect at an angle due to the functional requirement of the

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 1

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

mechanism, e.g. propeller shaft of an automobile), or have some axial displacement, a flexible
coupling should be used.

Perfect alignment

Laterally misaligned

Angularly misaligned

Axial displacement
Figure: 4.1 Perfect alignment and different misalignments

Most widely used Flexible Couplings are:

i. Oldham’s Coupling (laterally misaligned)

ii. Universal Coupling or Hooke’s Coupling (angularly misaligned)
iii. Bushed pin type Coupling (axial displacement)

Difference between Rigid and Flexible Couplings:

i. Rigid coupling cannot tolerate misalignment between the axes whereas Flexible
elements can tolerate 0.5° of angular misalignment and 5 𝑚𝑚 of axial displacement
between the shafts.
ii. Flexible coupling can absorb shocks and vibrations whereas rigid coupling can be used
only where the motion is free from shocks and vibrations.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 2

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

iii. Rigid coupling is simple and inexpensive whereas Flexible coupling is comparatively
costlier to additional parts.

Requirements of a good coupling:

i. Should capable of transmitting torque from driving shaft to the driven shaft.
ii. Should keep the two shafts in proper alignment.
iii. Should be easy to assemble and disassemble for the purpose of repairs and
alterations.
iv. Should be protected from failure of revolving parts like bolt heads, nuts, key heads
etc.

Muff Coupling:

Muff coupling is a type of rigid coupling. It is also called sleeve coupling or box coupling.

Figure: 4.2 Muff Coupling

The construction of the muff coupling is as shown in the Figure 4.2. It consists of a sleeve or
a hollow cylinder that is fitted over the ends of input and output shafts by means of a sunk
key. The torque is transmitted from the input shaft to the sleeve through the key. It is then
transmitted from the sleeve to the output shaft through the key.

The standard proportions for the dimensions of the sleeve are as follows:

Outer diameter of the sleeve, 𝐷 = (2𝑑 + 13) 𝑚𝑚

Axial length of the sleeve, 𝐿 = 3.5𝑑 𝑚𝑚

Where, 𝑑 = Diameter of the shaft in 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 3

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Problem:

Design a muff coupling, which is used to connect two steel shafts transmitting 𝟐𝟓 𝒌𝑾
power at 𝟑𝟔𝟎 𝒓. 𝒑. 𝒎. The shafts and key are made of plain carbon steel 𝟑𝟎𝑪𝟖 of yield stress
in tension and compression 𝟒𝟎𝟎 𝑵/𝒎𝒎𝟐. The sleeve is made of grey cast iron 𝑭𝑮 𝟐𝟎𝟎 of
ultimate tensile stress of 𝟐𝟎𝟎 𝑵/𝒎𝒎𝟐. The factor of safety for the shafts and key is 𝟒. For
sleeve, the factor of safety is 𝟔 based on ultimate strength.

Solution:

I. Given Data:

(i) Power transmitted, 𝑃 = 25 𝑘𝑊

(ii) Speed of the shaft, 𝑁 = 360 𝑟. 𝑝. 𝑚.

(iii) Yield stress of shaft and key material, 𝜎𝑦𝑡 = 𝜎𝑦𝑐 = 400 𝑁/𝑚𝑚2

(iv) Ultimate tensile stress of sleeve material (grey cast iron), 𝜎𝑢𝑡 = 200 𝑁/𝑚𝑚2

(v) Factor of safety for shaft and key, 𝑛1 = 4

(vi) Factor of safety for sleeve, 𝑛2 = 6

II. Material Selection:

(i) Material for shaft and key:

Allowable tensile and compressive stress,

𝜎𝑦𝑡 (= 𝜎𝑦𝑐 ) 400

𝜎𝑡 = 𝜎𝑐 = = = 100 𝑁/𝑚𝑚2
𝑛1 4

Allowable shear stress,

𝜎𝑦𝑡 (= 𝜎𝑦𝑐 ) 400

𝜏𝑠 = 𝜏𝑘 = 2 = 2 = 50 𝑁/𝑚𝑚2
𝑛1 4

(ii) Material for sleeve:

Allowable shear stress,

𝜎𝑢𝑡 200
𝜏𝑐 = 2 = 2 = 16.67 𝑁/𝑚𝑚2
𝑛2 6

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 4

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

III. Design of the Coupling:

(i) Diameter of the shaft (𝒅):

Torque transmitted by the shaft,

𝑃 × 60 × 1000 25 × 60 × 1000
𝑇= = = 663.145 𝑁𝑚 = 663145 𝑁𝑚𝑚
2𝜋𝑁 2𝜋 × 360
Torque transmitted by the shaft,
𝜋
𝑇= 𝜏 𝑑3
16 𝑠
𝜋
𝑂𝑟, 663145 = × 50 × 𝑑 3
16
𝑂𝑟, 𝑑 = 40.73 𝑚𝑚

Now, from TABLE 3.5(a), page no. 57 of DDHB,

The standard diameter of the shaft, 𝒅 = 𝟒𝟓 𝒎𝒎

(ii) Design of the sleeve:

Outer diameter of the sleeve, 𝐷 = (2𝑑 + 13) 𝑚𝑚 = 2 × 45 + 13 = 𝟏𝟎𝟑 𝒎𝒎

Axial length of the sleeve, 𝐿 = 3.5𝑑 = 3.5 × 45 = 157.5 = 𝟏𝟓𝟖 𝒎𝒎 (𝒔𝒂𝒚)

Checking for induced stress in the hub:

Torque transmitted by the sleeve,

𝜋 𝐷4 − 𝑑4
𝑇= 𝜏 ( )
16 𝑐𝑖 𝐷

𝜋 1034 − 454
663145 = × 𝜏𝑐𝑖 × ( )
16 103

Therefore, induced shear stress in the cast iron hub, 𝜏𝑐𝑖 = 3.21 𝑁/𝑚𝑚2

But, allowable shear stress in the cast iron, 𝜏𝑐 = 16.67 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the hub design is safe.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 5

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

(iii) Design of the key:

The length of key in each shaft is one-half of the length of the sleeve. Therefore,

Length of the key, 𝒍 = 𝐿/2 = 158/2 = 𝟕𝟗 𝒎𝒎

From the TABLE 4.1, page no. 69 of the DDHB, corresponding to the shaft diameter (𝑑 =
45 𝑚𝑚)

Width of the key, 𝒃 = 𝟏𝟒 𝒎𝒎 and

Height of the key, 𝒉 = 𝟗 𝒎𝒎

Therefore, dimensions of key are 𝟏𝟒 × 𝟗 × 𝟕𝟗 𝒎𝒎

Checking for induced shear stress in the key:

Considering the key in shearing, the torque transmitted is given by:

𝑑
𝑇 = 𝑙𝑏𝜏𝑘𝑖
2
45
𝑂𝑟, 663145 = 79 × 14 × 𝜏𝑘𝑖 ×
2
Therefore, induced shear stress in the key, 𝜏𝑘𝑖 = 26.65 𝑁/𝑚𝑚2

But, allowable shear stress in the key material, 𝜏𝑘 = 50 𝑁/𝑚𝑚2

Since 𝜏𝑘𝑖 < 𝜏𝑘 ,the key design is safe in shearing.

Checking for induced crushing stress in the key:

Considering the key in crushing, the torque transmitted is given by:

ℎ 𝑑
𝑇 = 𝑙 𝜎𝑘𝑖
2 2
9 45
𝑂𝑟, 663145 = 79 × × 𝜎𝑐𝑖 ×
2 2
Therefore, induced crushing stress in the key, 𝜎𝑐𝑖 = 82.91 𝑁/𝑚𝑚2

But, allowable crushing stress in the key material, 𝜎𝑐 = 100 𝑁/𝑚𝑚2

Since 𝜎𝑐𝑖 < 𝜎𝑐 ,the key design is safe in crushing.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 6

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

IV. Summary of Design:

Sl. No. Component Dimension Symbol Value

1. Shaft Diameter of Shaft 𝑑 45 𝑚𝑚
2. Sleeve Outer diameter of the sleeve 𝐷 103 𝑚𝑚
Axial length of the sleeve 𝐿 158 𝑚𝑚
3. Key Length of Key 𝑙 79 𝑚𝑚
Width of Key 𝑏 14 𝑚𝑚
Height of Key ℎ 9 𝑚𝑚

V. Diagram of the designed Coupling:

Figure: 4.3 Designed Muff Coupling

Clamp Coupling:

Clamp coupling is a rigid type of coupling. It is also called compression coupling or split muff
coupling.

Figure: 4.4 Clamp or Split Muff Coupling

In this coupling, the sleeve is made of two halves, that are split along a plane passing through
the axes of shafts. The construction of the clamp coupling is as shown in the Figure 4.4. The
two halves of the sleeve are clamped together by means of bolts. The number of bolts can be

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 7

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

4 or 8. They are always in multiples of 4. The bolts are placed in recesses formed in the sleeve
halves. A small clearance is provided in the parting plane between two halves. Therefore,
when the bolts are tightened, a force is exerted between the sleeve halves and the shaft. This
force caused by clamping of bolts creates frictional force on the surface of the shaft. The
torque is transmitted by means of frictional force on the surface of the shaft. There is also a
key between shafts and sleeve, that also transmits torque. It is not possible to find out what
percentage of torque is transmitted by friction or by the key. In design, it is assumed that total
torque is transmitted by friction as well as by the key. Therefore, the key is designed for total
torque. Also, the clamping bolts are designed for total torque. Power is transmitted from
input shaft to sleeve and from the sleeve to the output shaft by means of key and friction
between the sleeve halves and the shaft.

The main application of clamp coupling is for line shaft in power transmission. Now-a-days,
the line shaft and the clamp coupling have become obsolete.

The fundamental difference between the working of muff and clamp coupling is that, in muff
coupling, the torque is transmitted by shear resistance of keys, whereas in case of clamp
coupling, the torque is transmitted partly by means of friction between the sleeve halves and
the shaft and partly by shear resistance of key.

Clamp coupling is usually designed based on standard proportions for sleeve halves and
clamping bolts.

For sleeve halves,

Outer diameter of sleeve halves, 𝐷 = 2.5𝑑 𝑚𝑚

Length of sleeve, 𝐿 = 3.5𝑑 𝑚𝑚

Where, 𝑑 = Diameter of shaft in 𝑚𝑚

For clamping bolts,

Diameter of clamping bolt in 𝑚𝑚,

𝑑1 = 0.2𝑑 + 10 𝑚𝑚 𝑤ℎ𝑒𝑛 𝑑 < 55 𝑚𝑚

𝑑1 = 0.15𝑑 + 15 𝑚𝑚 𝑤ℎ𝑒𝑛 𝑑 > 55 𝑚𝑚

Where, 𝑑 = Diameter of shaft in 𝑚𝑚

Alternatively, the diameter of the clamping bolts can be calculated from first principle.

Let us assume that even with key, the torque is transmitted only through the friction between
the shaft and the coupling halves.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 8

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

The clamping tensile force of each bolt in Newton (N) is given by,
𝜋 2
𝑃1 = 𝑑 𝜎
4 1 𝑡
Where, 𝑑1 = Diameter of clamping bolt in 𝑚𝑚

𝜎𝑡 = Permissible tensile stress of clamping bolt material in 𝑁/𝑚𝑚2

It is assumed that half number of bolts give clamping pressure on input shaft and remaining
half on output shaft. Therefore, clamping force on each shaft is given by,

𝑃1 𝑛
𝑁=
2
Where, 𝑛 = Total number of clamping bolts

Figure: 4.5 Forces on each shaft

The frictional force (𝑓𝑁) is acting on each shaft, as shown in the Figure 4.5. the frictional
torque is given by,

𝑑 𝑑
𝑇 = 𝑓𝑁 ( ) + 𝑓𝑁 ( )
2 2
= 𝑓𝑁𝑑

𝑃1 𝑛
= 𝑓( )𝑑
2
𝑓𝑑𝑃1 𝑛
=
2
Where, 𝑓 = Coefficient of friction

Therefore, the tensile force on each bolt is given by,

2𝑇
𝑃1 =
𝑓𝑑𝑛

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 9

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Problem:

It is required to design a split muff coupling to transmit 𝟓𝟎 𝒌𝑾 power at 𝟏𝟐𝟎 𝒓. 𝒑. 𝒎. The

shafts, keys and clamping bolts are made of plain carbon steel 𝟑𝟎𝑪𝟖 of yield strength in
tension 𝟒𝟎𝟎 𝑵/𝒎𝒎𝟐. The yield strength in compression is 𝟏𝟓𝟎% of tensile yield strength.
The factor of safety for shafts, key and bolts is 𝟓. The number of clamping bolts is 𝟖. The
coefficient of friction between sleeve halves and the shaft is 𝟎. 𝟑.

(i) Calculate the diameter of input and output shafts.

(ii) Specify length and outer diameter of sleeve halves.

(iii) Find out the diameter of clamping bolts assuming that the power is transmitted by
friction.

(iv) Specify bolt diameter using standard empirical relations.

(v) Specify the size of key and check the dimensions for shear and compression criteria.

Solution:

I. Given Data:

(i) Power transmitted, 𝑃 = 50 𝑘𝑊

(ii) Speed of the shaft, 𝑁 = 120 𝑟. 𝑝. 𝑚.

(iii) Yield strength in tension for shaft, key, and bolt material, 𝜎𝑦𝑡 = 400 𝑁/𝑚𝑚2

(iv) Yield strength in compression for shaft, key and bolt material, 𝜎𝑦𝑐 = 1.5 × 𝜎𝑦𝑡 =
600 𝑁/𝑚𝑚2

(v) Factor of safety for shaft, key, and bolt, 𝑓𝑠 = 5

(vi) Number of clamping bolts, 𝑛 = 8

(vii) Coefficient of friction between sleeve halves and the shaft, 𝑓 = 0.3

II. Material Selection:

(i) Material for shaft, key, and bolt:

Allowable tensile stress,

𝜎𝑦𝑡 400
𝜎𝑡 = = = 80 𝑁/𝑚𝑚2
𝑓𝑠 5

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 10

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Allowable compressive stress,

𝜎𝑦𝑐 600
𝜎𝑐 = = = 120 𝑁/𝑚𝑚2
𝑓𝑠 5

Allowable shear stress,

𝜎𝑦𝑡 400
𝜏𝑠 = 𝜏𝑘 = 𝜏𝑏 = 2 = 2 = 40 𝑁/𝑚𝑚2
𝑓𝑠 5

(i) Diameter of input and output shafts (𝒅):

Torque transmitted by the shaft,

𝑃 × 60 × 1000 50 × 60 × 1000
𝑇= = = 3978.874 𝑁𝑚 = 3978874 𝑁𝑚𝑚
2𝜋𝑁 2𝜋 × 120
Torque transmitted by the shaft,
𝜋
𝑇= 𝜏 𝑑3
16 𝑠
𝜋
𝑂𝑟, 3978874 = × 40 × 𝑑 3
16
𝑂𝑟, 𝑑 = 79.72 𝑚𝑚

Now, from TABLE 3.5(a), page no. 57 of DDHB,

The standard diameter of the shaft, 𝒅 = 𝟖𝟎 𝒎𝒎

(ii) Length and outer diameter of sleeve halves:

Outer diameter of the sleeve half, 𝐷 = 2.5𝑑 = 2.5 × 80 = 𝟐𝟎𝟎 𝒎𝒎

Length of the sleeve, 𝐿 = 3.5𝑑 = 3.5 × 80 = 𝟐𝟖𝟎 𝒎𝒎

(iii) Diameter of clamping bolts:

The tensile force on each bolt is given by,

2𝑇
𝑃1 =
𝑓𝑑𝑛

2 × 3978874
=
0.3 × 80 × 8
= 41446.60 𝑁

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 11

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Also, the clamping tensile force of each bolt is given by,

𝜋 2
𝑃1 = 𝑑 𝜎
4 1 𝑡
Where, 𝑑1 = Diameter of clamping bolt in 𝑚𝑚

𝜎𝑡 = Permissible tensile stress of clamping bolt material in 𝑁/𝑚𝑚2

𝜋 2
∴ 𝑃1 = 𝑑 𝜎
4 1 𝑡
𝜋 2
⟹ 41446.60 = 𝑑 × 80
4 1
∴ 𝑑1 = 25.68 𝑚𝑚

From the TABLE 9.15, page no. 157 of DDHB,

The standard bolt diameter, 𝒅𝟏 = 𝟐𝟕 𝒎𝒎 (M27 bolt)

(iv) Bolt diameter using standard empirical relations

The empirical relation for diameter of clamping bolt in 𝑚𝑚, is given by

𝑑1 = 0.15𝑑 + 15 𝑚𝑚 𝑎𝑠, 𝑠ℎ𝑎𝑓𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑑 = 80 𝑚𝑚

⟹ 𝑑1 = 0.15 × 80 + 15 𝑚𝑚

∴ 𝑑1 = 27 𝑚𝑚

From the TABLE 9.15, page no. 157 of DDHB,

The standard bolt diameter, 𝒅𝟏 = 𝟐𝟕 𝒎𝒎 (M27 bolt)

(v) Size of key and checking the dimensions for shear and compression criteria

The length of key in each shaft is one-half of the length of the sleeve. Therefore,

Length of the key, 𝒍 = 𝐿/2 = 280/2 = 𝟏𝟒𝟎 𝒎𝒎

From the TABLE 4.1, page no. 69 of the DDHB, corresponding to the shaft diameter (𝑑 =
80 𝑚𝑚)

Width of the key, 𝒃 = 𝟐𝟐 𝒎𝒎 and

Height of the key, 𝒉 = 𝟏𝟒 𝒎𝒎

Therefore, dimensions of key are 𝟐𝟐 × 𝟏𝟒 × 𝟏𝟒𝟎 𝒎𝒎

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 12

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Checking for induced shear stress in the key:

Considering the key in shearing, the torque transmitted is given by:

𝑑
𝑇 = 𝑙𝑏𝜏𝑘𝑖
2
80
𝑂𝑟, 3978874 = 140 × 22 × 𝜏𝑘𝑖 ×
2
Therefore, induced shear stress in the key, 𝜏𝑘𝑖 = 32.30 𝑁/𝑚𝑚2

But, allowable shear stress in the key material, 𝜏𝑘 = 40 𝑁/𝑚𝑚2

Since 𝜏𝑘𝑖 < 𝜏𝑘 ,the key design is safe in shearing.

Checking for induced crushing stress in the key:

Considering the key in crushing, the torque transmitted is given by:

ℎ 𝑑
𝑇 = 𝑙 𝜎𝑘𝑖
2 2
14 80
𝑂𝑟, 3978874 = 140 × × 𝜎𝑐𝑖 ×
2 2
Therefore, induced crushing stress in the key, 𝜎𝑐𝑖 = 10.15𝑁/𝑚𝑚2

But, allowable crushing stress in the key material, 𝜎𝑐 = 120 𝑁/𝑚𝑚2

Since 𝜎𝑐𝑖 < 𝜎𝑐 ,the key design is safe in crushing.

Flange Coupling:

A Flange coupling usually applies to a coupling having two separate cast iron flanges.
Each flange is mounted on the shaft end and keyed to it. The faces are turned up at right angle
to the axis of the shaft. One of the flanges has a projected portion and the other flange has a
corresponding recess. This helps to bring the shafts into line and to maintain alignment. The
two flanges are coupled together by means of bolts and nuts. The flange coupling is adapted
to heavy loads and hence it is used on large shafting.

The flange couplings are of the following three types:

i. Unprotected type flange coupling
ii. Protected type flange coupling
iii. Marine type flange coupling

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 13

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Design of Flange Coupling:

Figure: 4.6 Flange Coupling

𝐴, 𝐵 =Clearances [𝐴 = 7 𝑚𝑚 𝑡𝑜 9 𝑚𝑚, 𝐵 = 15 𝑚𝑚 𝑡𝑜 19 𝑚𝑚]

𝑑 =Diameter of shaft or inner diameter of hub

𝐷 =Outer diameter of hub = 2𝑑

𝐿 =Length of hub = 1.5𝑑 =Effective length of key

𝑑1 =Nominal diameter of bolt

𝐷1 =Diameter of bolt circle = 3𝑑

𝑛 =Number of bolts
= 3 for 𝑑 ≤ 40 𝑚𝑚,
= 4 for 40 𝑚𝑚 < 𝑑 < 100 𝑚𝑚,
= 6 for 100 𝑚𝑚 < 𝑑 < 180 𝑚𝑚.
𝑡𝑓 =Thickness of flange = 0.5𝑑

𝜏𝑠 , 𝜏𝑏 , 𝜏𝑘 =Allowable shear stress for shaft, bolt and key materials respectively

𝜏𝑐 =Allowable shear stress for flange material i.e. Cast Iron

𝜎𝑐𝑏 , 𝜎𝑐𝑘 = Allowable crushing stress for bolt and key materials respectively

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 14

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

1. Design for Hub:

Outer diameter of the hub, 𝐷 = 2𝑑

Length of the hub, 𝐿 = 1.5𝑑

Checking for induced stress in the hub:

Considering the hub as a hollow shaft, transmitting the same torque (𝑇𝑚𝑎𝑥 ) as that by the
shaft

𝜋 𝐷4 − 𝑑4
𝑇𝑚𝑎𝑥 = 𝜏𝑐𝑖 ( )
16 𝐷

Where, 𝜏𝑐𝑖 = induced shear stress in the cast iron hub and is given by

16 𝐷
𝜏𝑐𝑖 = 𝑇𝑚𝑎𝑥 ( 4 )
𝜋 𝐷 − 𝑑4
If 𝜏𝑐𝑖 ≤ 𝜏𝑐 the hub design is safe, otherwise 𝐷 > 2𝑑

2. Design for key:

Length of the key, 𝑙 = 𝐿 = 1.5𝑑

Width (𝑏) and height (ℎ) of the key will be from the TABLE 4.1, page no. 69 of the DDHB
corresponding to the shaft diameter(𝑑).

Checking for induced shear stress in the key:

Considering the key in shearing, the maximum torque transmitted is given by:

𝑑
𝑇𝑚𝑎𝑥 = 𝑙𝑏𝜏𝑘𝑖
2

Where, 𝜏𝑘𝑖 = induced shear stress in the key and is given by

𝑇𝑚𝑎𝑥
𝜏𝑘𝑖 = 2
𝑙𝑏𝑑

If 𝜏𝑘𝑖 ≤ 𝜏𝑘 the key design is safe in shearing, otherwise

𝑇𝑚𝑎𝑥
𝑏=2
𝑙𝑑𝜏𝑘

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 15

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Checking for induced crushing stress in the key:

Considering the key in crushing, the maximum torque transmitted is given by:

ℎ 𝑑
𝑇𝑚𝑎𝑥 = 𝑙 𝜎𝑐𝑘𝑖
2 2

Where, 𝜎𝑐𝑘𝑖 = induced crushing stress in the key and is given by

𝑇𝑚𝑎𝑥
𝜎𝑐𝑘𝑖 = 4
𝑙𝑡𝑑

If 𝜎𝑐𝑘𝑖 ≤ 𝜎𝑐𝑘 the key design is safe in crushing, otherwise

𝑇𝑚𝑎𝑥
ℎ=4
𝑙𝑑𝜎𝑐𝑘

3. Design for flange:

Thickness of the flange, 𝑡𝑓 = 0.5𝑑

Checking for induced shear stress in the flange:

The flange at the junction of the hub is under shear while transmitting the torque, therefore
the maximum torque transmitted is given by:

𝐶𝑖𝑟𝑐𝑢𝑚𝑓𝑒𝑟𝑒𝑛𝑐𝑒 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑆ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠 𝑅𝑎𝑑𝑖𝑢𝑠

𝑇𝑚𝑎𝑥 = ( )×( )×( )×( )
𝑜𝑓 𝑡ℎ𝑒 ℎ𝑢𝑏 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑙𝑎𝑛𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑙𝑎𝑛𝑔𝑒 𝑜𝑓 𝑡ℎ𝑒 ℎ𝑢𝑏

𝐷 𝜋𝐷2
𝑂𝑟, 𝑇𝑚𝑎𝑥 = 𝜋𝐷𝑡𝑓 𝜏𝑐𝑖 = 𝜏 𝑡
2 2 𝑐𝑖 𝑓

Where, 𝜏𝑐𝑖 = induced shear stress in the cast iron flange and is given by

𝑇𝑚𝑎𝑥
𝜏𝑐𝑖 = 2
𝜋𝐷2 𝑡𝑓

If 𝜏𝑐𝑖 ≤ 𝜏𝑐 the flange design is safe, otherwise

𝑇𝑚𝑎𝑥
𝑡𝑓 = 2
𝜋𝐷2 𝜎𝑐

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 16

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

4. Design for bolts:

Diameter of bolt circle, 𝐷1 = 3𝑑

Number of bolts, 𝑛 = 3 for 𝑑 ≤ 40 𝑚𝑚,

= 4 for 40 𝑚𝑚 < 𝑑 < 100 𝑚𝑚,
= 6 for 100 𝑚𝑚 < 𝑑 < 180 𝑚𝑚.
We know that,
Load on each bolt
𝜋 2
= 𝑑 𝜏
4 1 𝑏
Total load on the entire bolts
𝜋 2
= 𝑑 𝜏 𝑛
4 1 𝑏
Therefore, the maximum torque transmitted is given by:
𝜋 2 𝐷1
𝑇𝑚𝑎𝑥 = 𝑑1 𝜏𝑏 𝑛
4 2
Therefore, diameter of the bolt,

𝑇𝑚𝑎𝑥
𝑑1 = √8
𝜋𝜏𝑏 𝑛𝐷1

The bolt diameter is standardized by using the TABLE 9.15, page no. 156,157 of DDHB.
Checking for induced crushing stress in the bolts:

We know that area resisting crushing of all the bolts = 𝑛𝑑1 𝑡𝑓

And crushing strength of all the bolts = 𝑛𝑑1 𝑡𝑓 𝜎𝑐𝑏𝑖
Therefore, maximum torque transmitted is given by:
𝐷1
𝑇𝑚𝑎𝑥 = 𝑛𝑑1 𝑡𝑓 𝜎𝑐𝑏𝑖
2
Where, 𝜎𝑐𝑏𝑖 = induced crushing stress in the bolts and is given by
𝑇𝑚𝑎𝑥
𝜎𝑐𝑏𝑖 = 2
𝑛𝑑1 𝑡𝑓 𝐷1
If 𝜎𝑐𝑏𝑖 ≤ 𝜎𝑐𝑏 , the bolt design is safe, otherwise
𝑇𝑚𝑎𝑥
𝑑1 = 2
𝑛𝑡𝑓 𝜎𝑐𝑏 𝐷1

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 17

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Problem:

It is required to design a rigid type of flange coupling to connect two shafts. The input shaft
transmits 𝟑𝟕. 𝟓 𝒌𝑾 power at 𝟏𝟖𝟎 𝒓. 𝒑. 𝒎. to the output shaft through the coupling. The
maximum torque is 𝟓𝟎% greater than the full-load torque.

Design and draw the coupling.

Solution:

I. Given Data:
a) Power to be transmitted, 𝑃 = 37.5 𝑘𝑊
b) Speed of the shaft, 𝑁 = 180 𝑟. 𝑝. 𝑚.
c) Maximum torque transmitted, 𝑇𝑚𝑎𝑥 = 1.5 × Mean torque (𝑇𝑚𝑒𝑎𝑛 )

II. Assumptions:
a) The material of the shaft, key and bolt is to be SAE 1045 annealed steel [TABLE 1.18,
page no. 473 of DDHB]
b) Considering steady load condition, the factor of safety for steel (𝑛1 ) is 4 [TABLE III-1,
page no. 477 of DDHB]
c) The material of the flange and hub is to be high grade gray cast iron [TABLE 1.17, page
no. 472 of DDHB]
d) Considering steady load condition, the factor of safety for cast iron (𝑛2 ) is 6 [TABLE
III-1, page no. 477 of DDHB]
e) For shaft a 25% reduction in strength is considered as key way allowance.

III. Material Selection:

a) Material for shaft
SAE 1045 annealed steel [TABLE 1.18, page no. 473 of DDHB]
Yield Stress:
Shear,
𝑀𝑁
𝜏𝑦 = 180 = 180 𝑁/𝑚𝑚2
𝑚2
Allowable Stress:

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 18

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Shear,
𝜏𝑦 180
𝜏𝑠 = × 0.75 = × 0.75 = 33.75 𝑁/𝑚𝑚2
𝑛1 4
b) Material for key and bolt
SAE 1045 annealed steel [TABLE 1.18, page no. 473 of DDHB]
Yield Stresses:
Tensile and compression,
𝑀𝑁
𝜎𝑦 = 310 = 310 𝑁/𝑚𝑚2
𝑚2
Shear,
𝑀𝑁
𝜏𝑦 = 180 = 180 𝑁/𝑚𝑚2
𝑚2
Allowable Stresses:
Tensile and compression,
𝜎𝑦 310
𝜎𝑘 = 𝜎𝑏 = = = 77.5 𝑁/𝑚𝑚2
𝑛1 4
Shear,
𝜏𝑦 180
𝜏𝑘 = 𝜏𝑏 = = = 45 𝑁/𝑚𝑚2
𝑛1 4
c) Material for flange and hub
High grade gray cast iron [TABLE 1.17, page no. 472 of DDHB]
Ultimate Stresses:
Tensile,
𝑀𝑁
𝜎𝑢 = 207 2
= 207 𝑁/𝑚𝑚2
𝑚
Therefore, ultimate shear stress,
𝜎𝑢 207
𝜏𝑢 = = = 103.5 𝑁/𝑚𝑚2
2 2
Allowable Stress:
Shear,
𝜏𝑢 103.5
𝜏𝑐 = = = 17.25 𝑁/𝑚𝑚2
𝑛2 6
IV. Design of the Coupling:
1) Diameter of the shaft (𝒅):

Mean torque transmitted by the shaft,

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 19

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

𝑃 × 60 × 1000 37.5 × 60 × 1000

𝑇𝑚𝑒𝑎𝑛 = = = 1989.437 𝑁𝑚 = 1989437 𝑁𝑚𝑚
2𝜋𝑁 2𝜋 × 180
Now,
𝑇𝑚𝑎𝑥 = 1.5 × 𝑇𝑚𝑒𝑎𝑛 = 1.5 × 1989437 = 2984155.5 𝑁𝑚𝑚

Maximum torque transmitted by the shaft,

𝜋
𝑇𝑚𝑎𝑥 = 𝜏 𝑑3
16 𝑠

𝜋
𝑂𝑟, 2984155.5 = × 33.75 × 𝑑 3
16

𝑂𝑟, 𝑑 = 76.65 𝑚𝑚

Now, from TABLE 3.5(a), page no. 57 of DDHB,

The standard diameter of the shaft, 𝒅 = 𝟖𝟎 𝒎𝒎

2) Design of the hub:

Outer diameter of the hub, 𝐷 = 2𝑑 = 2 × 80 = 160 𝑚𝑚

Length of the hub, 𝐿 = 1.5𝑑 = 1.5 × 80 = 120 𝑚𝑚

Checking for induced stress in the hub:

Maximum torque transmitted by the hub,

𝜋 𝐷4 − 𝑑4
𝑇𝑚𝑎𝑥 = 𝜏 ( )
16 𝑐𝑖 𝐷
𝜋 1604 − 804
𝑂𝑟, 2984155.5 = × 𝜏𝑐𝑖 × ( )
16 160

Therefore, induced shear stress in the cast iron hub, 𝜏𝑐𝑖 = 3.96 𝑁/𝑚𝑚2

But, allowable shear stress in the cast iron, 𝜏𝑐 = 17.25 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the hub design is safe.

3) Design of the key:

Length of the key, 𝒍 = 𝐿 = 1.5𝑑 = 1.5 × 80 = 𝟏𝟐𝟎 𝒎𝒎

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 20

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

From the TABLE 4.1, page no. 69 of the DDHB, corresponding to the shaft diameter (𝑑 =
80 𝑚𝑚)

Width of the key, 𝒃 = 𝟐𝟐 𝒎𝒎 and

Height of the key, ℎ = 14 𝑚𝑚

Checking for induced shear stress in the key:

Considering the key in shearing, the maximum torque transmitted is given by:

𝑑
𝑇𝑚𝑎𝑥 = 𝑙𝑏𝜏𝑘𝑖
2

80
𝑂𝑟, 2984155.5 = 120 × 22 × 𝜏𝑘𝑖 ×
2

Therefore, induced shear stress in the key, 𝜏𝑘𝑖 = 28.26 𝑁/𝑚𝑚2

But, allowable shear stress in the key material, 𝜏𝑘 = 45 𝑁/𝑚𝑚2

Since 𝜏𝑘𝑖 < 𝜏𝑘 ,the key design is safe in shearing.

Checking for induced crushing stress in the key:

Considering the key in crushing, the maximum torque transmitted is given by:

ℎ 𝑑
𝑇𝑚𝑎𝑥 = 𝑙 𝜎𝑘𝑖
2 2

14 80
𝑂𝑟, 2984155.5 = 120 × × 𝜎𝑘𝑖 ×
2 2

Therefore, induced crushing stress in the key, 𝜎𝑘𝑖 = 88.81 𝑁/𝑚𝑚2

But, allowable crushing stress in the key material, 𝜎𝑘 = 77.5 𝑁/𝑚𝑚2

Since 𝜎𝑘𝑖 > 𝜎𝑘 ,the key design is not safe in crushing.

Therefore, revised height of the key,

𝑇𝑚𝑎𝑥 2984155.5
𝒉=4 =4× = 15.04 = 𝟏𝟔 𝒎𝒎 (𝑠𝑎𝑦)
𝑙𝑑𝜎𝑘 120 × 80 × 77.5

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 21

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

4) Design of the flanges:

Thickness of the flange, 𝑡𝑓 = 0.5𝑑 = 0.5 × 80 = 40 𝑚𝑚

Checking for induced shear stress in the flange:

The maximum torque transmitted is given by:

𝜋𝐷2
𝑇𝑚𝑎𝑥 = 𝜏 𝑡
2 𝑐𝑖 𝑓

𝜋1602
𝑂𝑟, 2984155.5 = × 𝜏𝑐𝑖 × 40
2

Therefore, induced shear stress in the cast iron flange, 𝜏𝑐𝑖 = 1.85 𝑁/𝑚𝑚2

But, allowable shear stress in cast iron, 𝜏𝑐 = 17.25 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the flange design is safe.

5) Design of the bolts:

Diameter of bolt circle, 𝐷1 = 3𝑑 = 3 × 80 = 240 𝑚𝑚

Number of bolts, 𝑛 = 4 as diameter of the shaft, 𝑑 = 80 𝑚𝑚

The maximum torque transmitted is given by:

𝜋 2 𝐷1
𝑇𝑚𝑎𝑥 = 𝑑1 𝜏𝑏 𝑛
4 2

𝜋 2 240
𝑂𝑟, 2984155.5 = 𝑑1 × 45 × 4 ×
4 2

Therefore, diameter of the bolt, 𝑑1 = 13.26 𝑚𝑚

From the TABLE 9.15, page no. 156,157 of DDHB,

The standard bolt diameter, 𝒅𝟏 = 𝟏𝟒 𝒎𝒎 (M14 bolt)

Checking for induced crushing stress in the bolts:

The maximum torque transmitted is given by:

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 22

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

𝐷1
𝑇𝑚𝑎𝑥 = 𝑛𝑑1 𝑡𝑓 𝜎𝑏𝑖
2

240
𝑂𝑟, 2984155.5 = 4 × 14 × 40 × 𝜎𝑏𝑖 ×
2

Therefore, induced crushing stress in the bolts 𝜎𝑏𝑖 = 11.1 𝑁/𝑚𝑚2

But, Allowable crushing stress in the bolts, 𝜎𝑏 = 77.5 𝑁/𝑚𝑚2

Since, 𝜎𝑏𝑖 < 𝜎𝑏 , the bolt design is safe.

V. Summary of Design:

Sl. No. Component Dimension Symbol Value

1. Shaft Diameter of Shaft 𝑑 80 𝑚𝑚
2. Hub Outer Diameter of Hub 𝐷 160 𝑚𝑚
Length of Hub 𝐿 120 𝑚𝑚
3. Key Length of Key 𝑙 120 𝑚𝑚
Width of Key 𝑏 22 𝑚𝑚
Height of Key ℎ 16 𝑚𝑚
4. Flange Thickness of Flanges 𝑡𝑓 40 𝑚𝑚
5. Bolts Bolt circle diameter 𝐷1 240 𝑚𝑚
Number of Bolt 𝑛 4
Diameter of Bolts 𝑑1 14 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 23

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

VI. Diagram of the designed Flange Coupling:

Figure: 4.7 Designed Flange Coupling

Problem:

Design and draw a protective type of cast iron flange coupling for a steel shaft transmitting
𝟏𝟓 𝒌𝑾 at 𝟐𝟎𝟎 𝒓. 𝒑. 𝒎. and having an allowable shear stress of 𝟒𝟎 𝑵/𝒎𝒎𝟐 . The working
stress in the bolts should not exceed 𝟑𝟎 𝑵/𝒎𝒎𝟐 . Assume that the same material is used for
shaft and key and that the crushing stress is twice the value of its shear stress. The maximum
torque is 𝟐𝟓% greater than the full load torque. The allowable shear stress for cast iron is
𝟏𝟒 𝑵/𝒎𝒎𝟐 .

Solution:

I. Given Data:
a) Power to be transmitted, 𝑃 = 15 𝑘𝑊
b) Speed of the shaft, 𝑁 = 200 𝑟. 𝑝. 𝑚.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 24

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

c) Allowable shear stress of shaft material and key material, 𝜏𝑠 = 𝜏𝑘 = 40 𝑁/𝑚𝑚2

d) Allowable shear stress for bolt material, 𝜏𝑏 = 30 𝑁/𝑚𝑚2
e) Allowable crushing stress for bolt material, 𝜎𝑏 = 2𝜏𝑏 = 2 × 30 = 60 𝑁/𝑚𝑚2
f) Allowable crushing stress of key material, 𝜎𝑘 = 2𝜏𝑘 = 2 × 40 = 80 𝑁/𝑚𝑚2
g) The key is a square key, as crushing stress is twice the value of shear stress of the key
material.
h) Maximum torque transmitted, 𝑇𝑚𝑎𝑥 = 1.25 × 𝑇𝑚𝑒𝑎𝑛 (Mean torque)
i) Allowable shear stress for cast iron, 𝜏𝑐 = 14 𝑁/𝑚𝑚2
II. Design of the Coupling:
1) Diameter of the shaft (𝒅):

Mean torque transmitted by the shaft,

𝑃 × 60 × 1000 15 × 60 × 1000
𝑇𝑚𝑒𝑎𝑛 = = = 716.197 𝑁𝑚 = 716197 𝑁𝑚𝑚
2𝜋𝑁 2𝜋 × 200

Now,

𝑇𝑚𝑎𝑥 = 1.25 × 𝑇𝑚𝑒𝑎𝑛 = 1.25 × 716197 = 895246.25 𝑁𝑚𝑚

Maximum torque transmitted by the shaft,

𝜋
𝑇𝑚𝑎𝑥 = 𝜏 𝑑3
16 𝑠

𝜋
𝑂𝑟, 895246.25 = × 40 × 𝑑 3
16

𝑂𝑟, 𝑑 = 48.49 𝑚𝑚

Now, from TABLE 3.5(a), page no. 57 of DDHB,

The standard diameter of the shaft, 𝒅 = 𝟓𝟎 𝒎𝒎

2) Design of the hub:

Outer diameter of the hub, 𝐷 = 2𝑑 = 2 × 50 = 100 𝑚𝑚

Length of the hub, 𝐿 = 1.5𝑑 = 1.5 × 50 = 75 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 25

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Checking for induced stress in the hub:

Maximum torque transmitted by the hub,

𝜋 𝐷4 − 𝑑4
𝑇𝑚𝑎𝑥 = 𝜏 ( )
16 𝑐𝑖 𝐷

𝜋 1004 − 504
𝑂𝑟, 895246.25 = × 𝜏𝑐𝑖 × ( )
16 100

Therefore, induced shear stress in the cast iron hub, 𝜏𝑐𝑖 = 4.86 𝑁/𝑚𝑚2

But, allowable shear stress in the cast iron, 𝜏𝑐 = 14 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the hub design is safe.

3) Design of the key:

Length of the key, 𝒍 = 𝐿 = 1.5𝑑 = 1.5 × 50 = 𝟕𝟓 𝒎𝒎

From the TABLE 4.1, page no. 69 of the DDHB, corresponding to the shaft diameter (𝑑 =
50 𝑚𝑚)

Width of the key, 𝒃 = 𝟏𝟔 𝒎𝒎 and

Height of the key, 𝒉 = 𝒃 = 𝟏𝟔 𝒎𝒎 (As the key is a square key)

Checking for induced shear stress in the key:

Considering the key in shearing, the maximum torque transmitted is given by:

𝑑
𝑇𝑚𝑎𝑥 = 𝑙𝑏𝜏𝑘𝑖
2

50
𝑂𝑟, 895246.25 = 75 × 16 × 𝜏𝑘𝑖 ×
2

Therefore, induced shear stress in the key, 𝜏𝑘𝑖 = 29.84 𝑁/𝑚𝑚2

But, allowable shear stress in the key material, 𝜏𝑘 = 40 𝑁/𝑚𝑚2

Since 𝜏𝑘𝑖 < 𝜏𝑘 ,the key design is safe in shearing.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 26

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Checking for induced crushing stress in the key:

Considering the key in crushing, the maximum torque transmitted is given by:

ℎ 𝑑
𝑇𝑚𝑎𝑥 = 𝑙 𝜎𝑘𝑖
2 2

16 50
𝑂𝑟, 895246.25 = 75 × × 𝜎𝑘𝑖 ×
2 2

Therefore, induced crushing stress in the key, 𝜎𝑘𝑖 = 59.68 𝑁/𝑚𝑚2

But, allowable crushing stress in the key material, 𝜎𝑘 = 80 𝑁/𝑚𝑚2

Since 𝜎𝑘𝑖 < 𝜎𝑘 ,the key design is safe in crushing.

4) Design of the flanges:

Thickness of the flange, 𝑡𝑓 = 0.5𝑑 = 0.5 × 50 = 25 𝑚𝑚

Checking for induced shear stress in the flange:

The maximum torque transmitted is given by:

𝜋𝐷2
𝑇𝑚𝑎𝑥 = 𝜏 𝑡
2 𝑐𝑖 𝑓

𝜋1002
𝑂𝑟, 895246.25 = × 𝜏𝑐𝑖 × 25
2

Therefore, induced shear stress in the cast iron flange, 𝜏𝑐𝑖 = 2.28 𝑁/𝑚𝑚2

But, allowable shear stress in cast iron, 𝜏𝑐 = 14 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the flange design is safe.

5) Design of the bolts:

Diameter of bolt circle, 𝐷1 = 3𝑑 = 3 × 50 = 150 𝑚𝑚

Number of bolts, 𝑛 = 4 as diameter of the shaft, 𝑑 = 50 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 27

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

The maximum torque transmitted is given by:

𝜋 2 𝐷1
𝑇𝑚𝑎𝑥 = 𝑑1 𝜏𝑏 𝑛
4 2

𝜋 2 150
𝑂𝑟, 895246.25 = 𝑑1 × 30 × 4 ×
4 2

Therefore, diameter of the bolt, 𝑑1 = 11.25 𝑚𝑚

From the TABLE 9.15, page no. 156,157 of DDHB,

The standard bolt diameter, 𝒅𝟏 = 𝟏𝟐 𝒎𝒎 (M12 bolt)

Checking for induced crushing stress in the bolts:

The maximum torque transmitted is given by:

𝐷1
𝑇𝑚𝑎𝑥 = 𝑛𝑑1 𝑡𝑓 𝜎𝑏𝑖
2

150
𝑂𝑟, 895246.25 = 4 × 12 × 25 × 𝜎𝑏𝑖 ×
2

Therefore, induced crushing stress in the bolts 𝜎𝑏𝑖 = 9.95 𝑁/𝑚𝑚2

But, Allowable crushing stress in the bolts, 𝜎𝑏 = 60 𝑁/𝑚𝑚2

Since, 𝜎𝑏𝑖 < 𝜎𝑏 , the bolt design is safe.

6) Other proportions of the flange:

Outer diameter of the flange, 𝐷2 = 4𝑑 = 4 × 50 = 200 𝑚𝑚

Thickness of the protective circumferential flange, 𝑡𝑝 = 0.25𝑑 = 0.25 × 50 = 12.5 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 28

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

III. Summary of Design:

Sl. No. Component Dimension Symbol Value

1. Shaft Diameter of Shaft 𝑑 50 𝑚𝑚
2. Hub Outer Diameter of Hub 𝐷 100 𝑚𝑚
Length of Hub 𝐿 75 𝑚𝑚
3. Key Length of Key 𝑙 75 𝑚𝑚
Width of Key 𝑏 16 𝑚𝑚
Height of Key ℎ 16 𝑚𝑚
4. Flange Thickness of Flanges 𝑡𝑓 25 𝑚𝑚
5. Bolts Bolt circle diameter 𝐷1 150 𝑚𝑚
Number of Bolt 𝑛 4
Diameter of Bolts 𝑑1 12 𝑚𝑚
6. Outer diameter of the flange 𝐷2 200 𝑚𝑚
7. Thickness of the protective circumferential flange 𝑡𝑝 12.5 𝑚𝑚

IV. Diagram of the designed Flange Coupling:

Figure: 4.8 Designed Protective Type Flange Coupling

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 29

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Flexible Coupling:

Bushed-pin Flexible Coupling:

Figure: 4.9 Bushed-pin Flexible Coupling

A bushed-pin flexible coupling, as shown in the Figure 4.9, is a modification of the rigid
type of flange coupling. The coupling bolts are known as pins. The rubber or leather bushes
are used over the pins. The two halves of the coupling are dissimilar in construction. A
clearance (𝑒 = 5 𝑚𝑚) is left between the face of the two halves of the coupling. There is no
rigid connection between them and the drive takes place through the medium of the
compressible rubber or leather bushes.

In designing the bushed-pin flexible coupling, the proportions of the rigid type flange
coupling are modified. The main modification is to reduce the bearing pressure on the rubber
or leather bushes and it should not exceed 0.5 𝑁/𝑚𝑚2. In order to keep the low bearing
pressure, the pitch circle diameter and the pin size is increased.

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 30

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Let
𝑙 = Length of bush in the flange,
𝑑2 = Diameter of bush,
𝑝𝑏 = Bearing pressure on the bush or pin,
𝑛 = Number of pins, and
𝐷1 = Diameter of pitch circle of the pins.

Design of Bushed-pin Flexible Coupling:

1) Design for pins and rubber bush:

a) Number of pins, 𝑛 = 0.02𝑑 + 5 (𝑛 should be even)
0.5𝑑
b) Diameter of pin, 𝑑1 = (𝑑𝑏 should be of standard size)
√𝑛

c) Enlarge diameter of pin, 𝑑𝑏 = 𝑑1 + 2 × 𝑠𝑡𝑒𝑝 𝑠𝑖𝑧𝑒 [𝑠𝑡𝑒𝑝 𝑠𝑖𝑧𝑒 = 3 − 4 𝑚𝑚]

d) Overall diameter of rubber bush, 𝑑2 = 𝑑𝑏 + 2𝑡1 + 2𝑡2
Where, 𝑡1 =Tthickness of brass bush= 2 − 3 𝑚𝑚
𝑡2 =Thickness of rubber bush= 6 − 8 𝑚𝑚
e) Diameter of the pitch circle of the pins, 𝐷1 = 2𝑑 + 𝑑2 + 2𝑡2
𝐷1
f) Now, torque transmitted, 𝑇 = 𝑊 × 𝑛 ×
2
2𝑇
Therefore, bearing load acting on each pin, 𝑊 = 𝑛𝐷
1

Again, 𝑊 = 𝑝𝑏 × 𝑑2 × 𝑙
Where, 𝑝𝑏 = Bearing pressure on the bush or pin
𝑊
Therefore, length of bush in the flange, 𝑙 = 𝑝
𝑏 ×𝑑2

Checking for principal stress and maximum shear stress in the pin:
𝑊
Shear stress induced in the pin due to pure torsion in the coupling halves, 𝜏 = 𝜋
𝑑1 2
4

Figure: 4.10 Bending action on the pin

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 31

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Since the pin and the rubber or leather bush is not rigidly held in the left-hand flange,
therefore the tangential load (𝑊) at the enlarged portion will exert a bending action on the
pin as shown in Figure 4.10. The bush portion of the pin acts as a cantilever beam of length 𝑙.

Assuming a uniform distribution of the load 𝑊 along the bush, the maximum bending
moment on the pin,

𝑙
𝑀 = 𝑊 (2 + 𝑒)

Where, 𝑒 = clearance = 3 − 5 𝑚𝑚

𝜋
Section modulus of the pin section, 𝑍 = 32 𝑑1 3

𝑀
Therefore, bending stress induced, 𝜎𝑏 = 𝑍

𝜎𝑏 𝜎 2
Now, principal stress induced in the pin, 𝜎𝑚𝑎𝑥 = + √( 2𝑏 ) + 𝜏 2
2

𝜎 2
And maximum shear stress induced, τ𝑚𝑎𝑥 = √( 2𝑏 ) + 𝜏 2

If 𝜎𝑚𝑎𝑥 < Allowable tensile or compressive stress of the pin material

And τ𝑚𝑎𝑥 < Allowable shear stress of the pin material

Then the pin design is safe.

2) Design for Hub: Same as Flange Coupling

3) Design for Key: Same as Flange Coupling
4) Design for Flange: Same as Flange Coupling

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 32

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Problem:

Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 𝟑𝟐 𝒌𝑾 at 𝟗𝟔𝟎 𝒓. 𝒑. 𝒎. The overall torque is 𝟐𝟎% more than mean torque. The
material properties are as follows:
(a) The allowable shear and crushing stress for shaft and key material is 𝟒𝟎 𝑴𝑷𝒂 and
𝟖𝟎 𝑴𝑷𝒂 respectively.
(b) The allowable shear stress for cast iron is 𝟏𝟓 𝑴𝑷𝒂.
(c) The allowable bearing pressure for rubber bush is 𝟎. 𝟖 𝑵/𝒎𝒎𝟐 .
(d) The material of the pin is same as that of shaft and key.
Draw neat sketch of the coupling.

Solution:
I. Given Data:
a) Power to be transmitted, 𝑃 = 32 𝑘𝑊
b) Speed, 𝑁 = 960 𝑟. 𝑝. 𝑚.
c) Allowable shear stress of shaft and key material, 𝜏𝑠 = 𝜏𝑘 = 40 𝑁/𝑚𝑚2
d) Allowable shear stress of pin material, 𝜏𝑝 = 40 𝑁/𝑚𝑚2
e) Allowable crushing stress of shaft and key material, 𝜎𝑠 = 𝜎𝑘 = 80 𝑁/𝑚𝑚2
f) Allowable crushing stress of pin material, 𝜎𝑝 = 80 𝑁/𝑚𝑚2
g) The key is a square key, as crushing stress is twice the value of shear stress of the key
material.
h) Maximum torque transmitted, 𝑇𝑚𝑎𝑥 = 1.20 × 𝑇𝑚𝑒𝑎𝑛 (Mean torque)
i) Allowable shear stress for cast iron, 𝜏𝑐 = 15 𝑁/𝑚𝑚2
j) The allowable bearing pressure for rubber bush, 𝑝𝑏 = 0.8 𝑁/𝑚𝑚2.
II. Design of the Coupling:
1) Diameter of the shaft (𝒅):

Mean torque transmitted by the shaft,

𝑃 × 60 × 1000 32 × 60 × 1000
𝑇𝑚𝑒𝑎𝑛 = = = 318.310 𝑁𝑚 = 318310 𝑁𝑚𝑚
2𝜋𝑁 2𝜋 × 960

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 33

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Now,

𝑇𝑚𝑎𝑥 = 1.20 × 𝑇𝑚𝑒𝑎𝑛 = 1.20 × 318310 = 381972 𝑁𝑚𝑚

Maximum torque transmitted by the shaft,

𝜋
𝑇𝑚𝑎𝑥 = 𝜏 𝑑3
16 𝑠

𝜋
𝑂𝑟, 381972 = × 40 × 𝑑 3
16

𝑂𝑟, 𝑑 = 36.50 𝑚𝑚

Now, from TABLE 3.5(a), page no. 57 of DDHB,

The standard diameter of the shaft, 𝒅 = 𝟒𝟎 𝒎𝒎

2) Design for pins and rubber bush:

a) Number of pins,
𝑛 = 0.02𝑑 + 5 = 0.02 × 40 + 5 = 5.8 = 6 (𝑠𝑎𝑦)
b) Diameter of pin,
0.5𝑑 0.5 × 40
𝑑1 = = = 8.16 𝑚𝑚
√𝑛 √6
Standard pin diameter, 𝑑1 = 20 𝑚𝑚
c) Enlarge diameter of pin,
𝑑𝑏 = 𝑑1 + 2 × 𝑠𝑡𝑒𝑝 𝑠𝑖𝑧𝑒 [𝑠𝑡𝑒𝑝 𝑠𝑖𝑧𝑒 = 2 − 4 𝑚𝑚]
Assuming, 𝑠𝑡𝑒𝑝 𝑠𝑖𝑧𝑒 = 2 𝑚𝑚,
𝑑𝑏 = 20 + 2 × 2 = 24 𝑚𝑚
d) Overall diameter of rubber bush,
𝑑2 = 𝑑𝑏 + 2𝑡1 + 2𝑡2
Where, 𝑡1 =Tthickness of brass bush= 2 − 3 𝑚𝑚
𝑡2 =Thickness of rubber bush= 6 − 8 𝑚𝑚
Assuming, 𝑡1 = 2 𝑚𝑚 and 𝑡2 = 6 𝑚𝑚
𝑑2 = 𝑑𝑏 + 2𝑡1 + 2𝑡2 = 24 + 2 × 2 + 2 × 6 = 40 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 34

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

e) Diameter of the pitch circle of the pins,

𝐷1 = 2𝑑 + 𝑑2 + 2𝑡2 = 2 × 40 + 40 + 2 × 6 = 132 𝑚𝑚
f) Now, maximum torque transmitted,
𝐷1
𝑇𝑚𝑎𝑥 = 𝑊 × 𝑛 ×
2
Therefore, bearing load acting on each pin,
2𝑇𝑚𝑎𝑥 2 × 381972
𝑊= = = 964.58 𝑁
𝑛𝐷1 6 × 132
Again,
𝑊 = 𝑝𝑏 × 𝑑2 × 𝑙
Where, 𝑝𝑏 = Bearing pressure on the bush or pin
Therefore, length of bush in the flange,
𝑊 964.58
𝑙= = = 30.14 𝑚𝑚 = 32 𝑚𝑚
𝑝𝑏 × 𝑑2 0.8 × 40
Therefore,
𝑊 = 𝑝𝑏 × 𝑑2 × 𝑙 = 0.8 × 40 × 32 = 1024 𝑁

Checking for principal stress and maximum shear stress induced in the pin:

Shear stress induced in the pin due to pure torsion in the coupling halves,

𝑊 1024
𝜏=𝜋 2=𝜋 = 3.26 𝑁/𝑚𝑚2
2
4 𝑑1 4 20

The maximum bending moment on the pin,

𝑙
𝑀 = 𝑊 ( + 𝑒)
2

Where, 𝑒 = clearance = 3 − 5 𝑚𝑚

Assuming 𝑒 = 5 𝑚𝑚

32
𝑀 = 1024 × ( + 5) = 21504 𝑁𝑚𝑚
2

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 35

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Section modulus of the pin section,

𝜋 3 𝜋
𝑍= 𝑑1 = 203 = 785.4 𝑚𝑚3
32 32

Therefore, bending stress induced,

𝑀 21504
𝜎𝑏 = = = 27.38 𝑁/𝑚𝑚2
𝑍 785.4

Now, principal stress induced in the pin,

𝜎𝑏 𝜎𝑏 2 27.38 27.38 2
𝜎𝑚𝑎𝑥 = + √( ) + 𝜏 2 = + √( ) + 3.262 = 27.76 𝑁/𝑚𝑚2
2 2 2 2

And maximum shear stress induced,

𝜎𝑏 2 27.38 2
τ𝑚𝑎𝑥 = √( ) + 𝜏 2 = √( ) + 3.262 = 14.07 𝑁/𝑚𝑚2
2 2

But, Allowable crushing stress of pin material, 𝜎𝑝 = 80 𝑁/𝑚𝑚2

And allowable shear stress of pin material, 𝜏𝑝 = 40 𝑁/𝑚𝑚2

Since, 𝜎𝑚𝑎𝑥 < 𝜎𝑝 and τ𝑚𝑎𝑥 < 𝜏𝑝 , the pin design is safe.

3) Design of the hub:

Outer diameter of the hub, 𝐷 = 2𝑑 = 2 × 40 = 80 𝑚𝑚

Length of the hub, 𝐿 = 1.5𝑑 = 1.5 × 40 = 60 𝑚𝑚

Checking for induced stress in the hub:

Maximum torque transmitted by the hub,

𝜋 𝐷4 − 𝑑4
𝑇𝑚𝑎𝑥 = 𝜏𝑐𝑖 ( )
16 𝐷

𝜋 804 − 404
381972 = × 𝜏𝑐𝑖 × ( )
16 80

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 36

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Therefore, induced shear stress in the cast iron hub, 𝜏𝑐𝑖 = 4.05 𝑁/𝑚𝑚2

But, allowable shear stress in the cast iron, 𝜏𝑐 = 15 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the hub design is safe.

4) Design of the key:

Length of the key, 𝒍𝒌 = 𝐿 = 1.5𝑑 = 1.5 × 40 = 𝟔𝟎 𝒎𝒎

From the TABLE 4.1, page no. 69 of the DDHB, corresponding to the shaft diameter (𝑑 =
40 𝑚𝑚)

Width of the key, 𝒃 = 𝟏𝟐 𝒎𝒎 and

Height of the key, 𝒉 = 𝒃 = 𝟏𝟐 𝒎𝒎 (As the key is a square key)

Checking for induced shear stress in the key:

Considering the key in shearing, the maximum torque transmitted is given by:

𝑑
𝑇𝑚𝑎𝑥 = 𝑙𝑘 𝑏𝜏𝑘𝑖
2

40
𝑂𝑟, 381972 = 60 × 12 × 𝜏𝑘𝑖 ×
2

Therefore, induced shear stress in the key, 𝜏𝑘𝑖 = 26.53 𝑁/𝑚𝑚2

But, allowable shear stress in the key material, 𝜏𝑘 = 40 𝑁/𝑚𝑚2

Since 𝜏𝑘𝑖 < 𝜏𝑘 ,the key design is safe in shearing.

Checking for induced crushing stress in the key:

Considering the key in crushing, the maximum torque transmitted is given by:

𝑡 𝑑
𝑇𝑚𝑎𝑥 = 𝑙𝑘 𝜎𝑘𝑖
2 2

12 40
𝑂𝑟, 381972 = 60 × × 𝜎𝑘𝑖 ×
2 2

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 37

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

Therefore, induced crushing stress in the key, 𝜎𝑘𝑖 = 53.05 𝑁/𝑚𝑚2

But, allowable crushing stress in the key material, 𝜎𝑘 = 80 𝑁/𝑚𝑚2

Since 𝜎𝑘𝑖 < 𝜎𝑘 ,the key design is safe in crushing.

5) Design of the flanges:

Thickness of the flange, 𝑡𝑓 = 0.5𝑑 = 0.5 × 40 = 20 𝑚𝑚

Checking for induced shear stress in the flange:

The maximum torque transmitted is given by:

𝜋𝐷2
𝑇𝑚𝑎𝑥 = 𝜏 𝑡
2 𝑐𝑖 𝑓
𝜋802
𝑂𝑟, 381972 = × 𝜏𝑐𝑖 × 20
2
Therefore, induced shear stress in the cast iron flange, 𝜏𝑐𝑖 = 1.90 𝑁/𝑚𝑚2

But, allowable shear stress in cast iron, 𝜏𝑐 = 15 𝑁/𝑚𝑚2

Since 𝜏𝑐𝑖 < 𝜏𝑐 , the flange design is safe.

III. Summary of Design:

Sl. No. Component Dimension Symbol Value

1. Shaft Diameter of Shaft 𝑑 40 𝑚𝑚
2. Pins and rubber bush Number of pins 𝑛 6
Diameter of pin 𝑑1 20 𝑚𝑚
Enlarge diameter of pin 𝑑𝑏 24 𝑚𝑚
Overall diameter of rubber 𝑑2 40 𝑚𝑚
bush
Pitch circle diameter of the pins 𝐷1 132 𝑚𝑚
length of bush in the flange 𝑙 32 𝑚𝑚
3. Hub Outer Diameter of Hub 𝐷 80 𝑚𝑚
Length of Hub 𝐿 60 𝑚𝑚
4. Key Length of Key 𝑙𝑘 60 𝑚𝑚
Width of Key 𝑏 12 𝑚𝑚
Height of Key ℎ 12 𝑚𝑚
5. Flange Thickness of Flanges 𝑡𝑓 20 𝑚𝑚

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 38

 DEPARTMENT OF MECHANICAL ENGINEERING
JORHAT ENGINEERING COLLEGE, JORHAT-785 007, ASSAM

IV. Diagram of the designed Coupling:

Figure: 4.11 Designed Bushed-pin Type of Flexible Coupling

Module 4: Coupling (Design of Rigid and Flexible Couplings) Page 39